Method of stretching and attaching an insulator to a supporting spring structure



Feb. 23, 1965 R. P. DOERER 3,170,223

METHOD OF STRETCHING AND ATTACHING AN INSULATOR TO A SUPPORTING SPRINGSTRUCTURE 13, 1961 2 Sheets-Sheet 1 Original Filed Nov.

IEE L INVENTOR.

s M a AW Feb. 23, 1965 R. P. DOERER 3,170,223

METHOD OF STRETCHING AND ATTACHING AN INSULATOR TO A SUPPORTING SPRINGSTRUCTURE Original Filed Nov. 13, 1961 2 Sheets-Sheet 2 l as m Iii-=15fiE-mlfl7 27 /3 .22 Z/ E 5 3%.: a Lg 4; u E WM M W =15 I @245 mafia; f

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// R/CHJFD 2 0042 451? W211, MM? 4 United States Patent 3,176,223 ETHUI)GE STRETCHING AND ATTAQHING AN INSULA'IGR TO A SUIPQRTING SPRINGSTRUQTURE Richard P. Doerer, Ypsilanti, Mich, assignor to Van DresserSpecialty Corporation, Warren, Mich., a corporation of Michigan 7Original application Nov. 13, 1961, Ser. No. 151,773, new Patent No.3,132,353, dated May '12, 1964. Divided and this application Ian. 28,M63, Ser. No. 254,354

4 Claims. (Cl. 29-911) This invention relates to a method of stretchingand attaching an insulator to a supporting spring structure of anupholstered assembly, and is a division of my copending applicationSerial No. 151,773, filed November 13, 1961, now Patent No. 3,132,353,granted May 12, 1964.

One of the essential objects of the invention is to provide a method ofapplying to the border frame of the supporting spring structure of anupholstered assembly an elongated, flexible, stretchable insulatorinitially having in its free state an overall dimension in one directionless than the minimum dimension of the border frame in the aforesaiddirection, comprising securing one edge of the insulator to one edge ofthe border frame, stretching the insulator in the said one direction,and securing the opposite edge of the stretched insulator to theopposite edge of the border frame.

Another object is to provide a method of applying to the border frame ofthe supporting spring structure of an upholstered assembly a flexible,stretchable insulator at least a portion of which extending in onedirection between opposite edges of said insulator has in its free statea dimension in said one direction less than the dimension in the saidone direction of the corresponding portion of the border frame,comprising securing one of said edges of the insulator to one edge ofthe border frame, stretching the insulator in said one direction, andsecuring the opposite edge of the stretched insulator to the oppositeedge of the border frame.

Other objects, advantages, and novel details of construction of theinvention willbe made more apparent as this description proceeds,especially when considered in connection with the accompanying drawingswherein:

FIGURE 1 is a perspective View of an upholstered assembly provided withan extensible insulator embodying my invention, and showing parts brokenaway and in section.

FIGURE 2 is a top plan view of the insulator, shown overlying asupporting spring structure of an upholsteredassembly before beingstretched'to a configuration conforming to the contour of the borderframe of the supporting spring structure.

FIGURE 3 is a sectional view taken on the line 33 of FIGURE 2.

FIGURE 4 is a view similar to FIGURE 2 but shows the insulator after ithas been bodily stretched to conform to the contour of the border frameof the supporting spring structure and marginally secured thereto.FIGURES 5-11, inclusive, are sectional views taken 3,170,223. PatentedFeb. 23, 1&65

a modified construction, being shown in its initial free state.

FIGURE 17 is a top plan view of the insulator of FIGURE 16 after it hasbeen stretched to a configuration conforming to the contour of theborder frame of the supporting spring structure, shown marginallysecured to the border frame.

FIGURES 18 and 19 are sectional views taken through reinforcing strandsof different diameters.

In the drawings, A is an elongated, rectangular, substantiallyhorizontally extending, flexible, bodily stretchable, shcet-lilceinsulator embodying my invention disposed between an overlying padding Bfor an exterior trim material C and an elongated underlying supportingspring structure D of'an upholstered assembly.

As shown, the insulator A includes an elongated, substantiallyrectangular extensible sheet 10 of flexible material, and separateelongated, laterally spaced, parallel, stretchable, resilient,reinforcing strands 11 of uniform length threaded lengthwise through theextensible rectangular sheet 10.

The rectangular sheet 16) is formed with a longitudinal series oftransverse pleats or undulations 12, and the reinforcing strands 11 arepreferably in the form of helically coiled wires at right angles to thepleats. The strands 11 thread through the pleats 1.2 so that alternatepleats lie on opposite sides of the strands. In the initial respectivelyon the lines 55, 66, 7-7, 8-8-, 9-9,

1(l10, and 1111 of FIGURE4;

FIGURE 12 is a sectional view taken on the line 12-42 V of FIGURE 4. l va FIGURE 13 is similar to FIGURE 12 but shows a modification.

FIGURE 14 is similar to FIGURES 12 shows still another modification.

FIGURE 15 is a sectional view taken on the line 15-15 of FIGURE 2.

2 FIGURE 16 is a top plan view of an insulator having and 13 but freestate of the insulator shown in FIGURE 2, the undulations or pleats 12are relatively deep and close together, substantially as shown in FIGURE5, and the reinforcing strands are all of the same pitch, being suitablycoiled and having a plurality of convolutions between successiveundulations or pleats of the sheet. It will be understood that in someinstances the pleats may extend longitudinally of the sheet and thestrands may extend transversely of the sheet and may be threaded throughthe longitudinally extending pleats.

The insulator A also includes a pair of elongated anchorage portions 13,one along each end of and separate from the sheetltl. Alternatively,each anchorage portion may be integral with and formed as a rolled orfolded end of the sheet, as indicated at 1% in dotted lines in FIGURE15. The reinforcing strands 11 are terminally provided at each end withreturn bent portions 14 which are clamped around the anchorage portions13.

The supporting spring structure includes an elongated substantiallyhorizontal border frame 18 of predetermined length, made to the desiredconfiguration and area from a wire element or the like and havingcontoured ends 20 and 21. It will be noted that the rectangularinsulator It has, in its initial free state shown in FIG- URE 2, anoverall length less than the minimum lengthwise dimension of the borderframe, measured between the ends 20 and 21 thereof.

A plurality of laterally spaced clips 15 are provided along each end ofthe insulator, each clip being formed at one end with a return bentportion 16 which is clamped around an anchorage portion 13, and beingformed at the opposite end with a return bent portion 17 for quickattachment to the'border frame 18 of the support ing spring structure D.The clips 15 are preferably of the clinch type, wherein the .return bentportion 17. has i i FIGURE 13 illustrates a resilient snap-on type clip15".,

a plurality of which can be used in place of clips 15. The return bentportion 17' of each clip 15' has a flared.

end 18 so that the border frame can snap into the return bent portion,facilitated by the flared end 18', and.

be resiliently held therein. Otherwise, clips 15' are exactly like theclips 15 and are secured to an anchorage portion 13 of the insulator inthe same way.

The clips 15 or 15 may be permanently clamped on the anchorage portions13 of the insulator for quick attachment of the insulator to the borderframe of the supporting spring structure.

Although the various elements of my insulator may be formed of anysuitable material for the purposes set forth, the rectangular sheet ispreferably formed of burlap, and the reinforcing strands 11 arepreferably formed of wire of circular cross section. The anchorageportions 13 are preferably formed of rolled or folded burlap, and theclips are preferably formed of fiat or round wire stock.

In order to apply the insulator A to the border frame 18 of thesupporting spring structure, one end of the insulator is attached to oneend 20 or 21 of the border frame by engaging the return bent portions.17 or 17' of the clips or 15 over the corresponding end of the borderframe. The insulator is then bodily stretched horizontally to aconfiguration conforming to the contour of the horizontal border frameand its opposite end secured to the opposite end of the border frame byengaging the return bent portions 17 or 17' over the opposite end of theborder frame.

As an alternative, the clips 15 may be replaced by hog rings 22. Aplurality of spaced hog rings along the length of each anchorage portion13 will be provided to embrace both the anchorage portion and the borderframe at the corresponding end of the supporting spring structure. Thisis shown in FIGURE 14. The hog rings, while of anysuitable flexible,deformable material, are preferably of vmetal and are formed as an openloop capable of being deformed to cross or open the ends to secure theanchorage portion of the insulator to or release it from the borderframe.

The same procedure is employed to secure the insulator to the borderframe by hog rings; that is, the hog rings encircling the anchorageportion at one end of the insulator will be clinched about thecorresponding end of the border frame, the insulator will be bodilystretched to a configuration conforming to the contour of the borderframe, and thereafter the hog rings encircling the other anchorageportion of the insulator will be clinched about the other end of theborder frame.

Either before or after the ends of the insulator are secured by theclips or hog rings as described above, the longitudinal edges of theinsulator will be secured to the parallel sides 23 and 24 of the borderframe 13 by additional spaced hog rings 22. The hog rings 22 along thelongitudinal edges of the insulator pierce the body of the sheet 10 andencircle the sides 23 and 24 of the border frame. It will be noted thatthe width of the insulator A, in its free state, is substantially equalto the distance between the sides 23 and 24 of the border frame.

Since the ends and 21 of the border frame are contoured or curved asshown in FIGURES 2 and 4, different longitudinal segments of theinsulator will be stretched different amounts (FIGS 4-11). Referring toFIGURES 4 and 11, it will be seen that along side 23 of the borderframe, the sheet and coiled reinforcing strands are stretchedconsiderably. However, both the pleated fabric and reinforcing strands,although bodily stretched, remain in an undulated condition. Referringto FIGURES 4 and 5, it will be noted that along the opposite side 24 ofthe border frame, the pleated fabrica and the coiled reinforcing strandsare extended very little if at all. Hence in this section of theinsulator,

the pleats or undulations in the fabric are deep andthe reinforcingstrands are more closely coiled. Between the opposite longitudinal edgesof the insulator, the fabric and reinforcing strands are stretchedvarying amounts,

as will be apparent from an inspection of FIGURES 4 and 6-10.

It will be observed that both the fabric sheet and the reinforcingstrands remain in an undulated condition after application to the borderframe of the supporting spring structure at all points, although at somepoints the undulations are deeper or more closely formed than at others.Hence, the insulator, when applied to the supporting spring structure asshown in FIGURE 4, remains stretchable at all points to compensate for10- calized loads imposed thereon.

Referring to FIGURES 16 and 17, an insulator A of modified constructionis shown. This insulator differs from the one shown in FIGURES 24 inthat the reinforcing strands 11', in their initial free state, are notall of the same pitch. As noted in FIGURE 16, the strands near onelongitudinal edge 26 of the insulator are of relatively small pitch andthe strands near the opposite longitudinal edge 27 are of a relativelygreater pitch. The intermediate strands are of progressively greaterpitch from the longitudinal edge 2s to the other edge 27. In thisinstance, the pitch of the strands has been varied so that when theinsulator is stretched bodily and secured to the border frame, as inFIGURE 17, the variously stretched strands will all be of the same pitchand hence will simulate strands of the same pitch. It will beunderstood, of course, that other variations in the pitch of the strandsmay be made to compensate for heavy localized loads which may occur incertain areas of the upholstered assembly.

While both the insulator A shown in FIGURES 2, 3, and 4 and theinsulator A shown in FIGURES 16 and 17 may have reinforcing strand-s allof the same circular cross section, the cross section of the variousstrands may be varied to compensate for heavy localized loads inparticular areas of the upholstered assembly. Thus, as shown inFIGURES1S and 19 one strand may be of a greater diameter than another 11b. Thestrands 11a and 1112 may be considered to be different strands of eitherof the insulators A or A. Hence, the insulator A for example, shown inFIGURES l6 and 17, may have reinforcing strands which, in their freestate, are of different pitch, and those strands may be of differentdiameter as well.

What I claim as my invention is:

1. A method of forming and applying an elongated flexible, sheet-likeinsulator to an elongated border frame of a supporting spring structureof an upholstered assembly; comprising providing a preformed insulatorincluding an elongated substantially rectangular sheet of flexiblematerial provided with transverse undulations and having an initiallengthwise dimension less than the lengthwise dimension of said borderframe, and also including a plurality of elongated, laterally spacedsubstantially parallel, stretchable resilient reinforcing strandsthreaded through said undulations and extending longitudinally of saidsheet and having anchorage members at the opposite ends of said sheetextending transversely thereof to which said strands are terminallyconnected, securing one of said anchorage members to one end of saidborder frame, then longitudinally stretching said preformed insulatorwhereby to place said strands in tension and to increase the lengthwisedimension of said strands and said sheet to approximately the lengthwisedimension of said border frame, and thereafter while said strands are intension and said strands and sheets are increased in length asaforesaid, securing the other of said anchorage'members to the oppositeend of said border frame.

2. The method defined in claim 1 wherein said anchorage members aresecured as aforesaid to the ends of said border frame in a manner suchthat said anchorage members and the ends of said sheet conform substantially in contour to the ends of said border frame.

3. A method of forming and applying an elongated flexible, sheet-likeinsulator to an elongated border frame of a supporting spring structureof an upholstered assembly; comprising providing a preformed insulatorincluding an elongated rectangular sheet of flexible burlap materialprovided with transverse undulations and having an initiallengthwisedimension less than the lengthwise dimension of said borderframe, and also including a pluralityof elongated, laterally spaced,substantially parallel,

stretchable, resilient reinforcing strands threaded through saidundulations and extendinglongitudinally ofsaid sheet and havinganchorage members atthe opposite ends of said sheet which are separatefrom and extend Y transversely of'said sheet and to'which said strandsare terminally connected, securing one of said anchorage Wise dimensionof said border frame, and also including a plurality of elongated,laterally spaced, substantially parallel, stretchable, resilientreinforcing strands threaded through said undulationsand extendinglongitudinallyof said sheet and having anchorage members at the oppositeends of said sheet which are integral with and ex tend transverselyofsaid' sheet and ,t hichsaidstrands are terminally connected, securingone of said anchorage v members to one end of said border frame,thenlongitudinally stretching said preformed insulator whereby to placesaid strands in tension and to increase the length- I wise dimension ofsaid strands and said sheet to approximembers to one end of said borderframe, then longitudinally stretching said preformed insulator whereby"to placeosaid strands in tension and toincrease the length Wisedimensionjofsaid strands and said sheet to approximately the lengthwisedimension of said border frame, and thereafter While said strands are intension and said strands and sheet are increased .in length asaforesaid, securing the other of said anchorage members to the oppositeend; of said border frame, o

4. A method of forming and applying an elongated flexible, sheet-likeinsulator to an elongated border frame material provided with transverseundulations and having an initial lengthwise dimension less thanthelengtha securing the otherof said anchorage members to the 0pof asupporting spring structure of an upholstered assern- .bly; comprisingprovidinga preformedinsulatorinclud- .ing an elongated rectangular sheet"of flexible burlap mately the lengthwise dimension of said borderframe,

and thereafter, while said strands are in tension and said strands andsheet are increased in length as aforesaid,

po'siteend of said border frame.v

References Cited'by the Examiner V UNITED STATES PATENTS WHITMORE A.WILTZ, Primary Examiner.

THOMAS H. EAGER, Examiner.

1. A METHOD OF FORMING AND APPLYING AN ELONGATED FLEXIBLE, SHEET-LIKEINSULATOR TO AN ELONGATED BORDER FRAME OF A SUPPORTING SPRING STRUCTUREOF AN UPHOLSTERED ASSEMBLY; COMPRISING PROVIDING A PREFORMED INSULATORINCLUDING AN ELONGATED SUBSTANTIALLY RECTANGULAR SHEET OF FLEXIBLEMATERIAL PROVIDED WITH TRANSVERSE UNDULATIONS AND HAVING AN INITIALLENGTHWISE DIMENSION LESS THAN THE LENGTHWISE DIMENSION OF SAID BORDERFRAME, AND ALSO INCLUDING A PLURALITY OF ELONGATED, LATERALLY SPACEDSUBSTANTIALLY PARALLEL, STRETCHABLE RESILIENT REINFORCING STRANDSTHREADED THROUGH SAID UNDULATIONS AND EXTENDING LONGITUDINALLY OF SAIDSHEET AND HAVING ANCHORAGE MEMBERS AT THE OPPOSITE ENDS OF SAID SHEETEXTENDING TRANSVERSELY THEREOF TO WHICH SAID STRANDS ARE TERMINALLYCONNECTED, SECURING ONE OF SAID ANCHORAGE MEMBERS TO ONE END OF SAIDBORDER FRAME, THEN LONGITUDINALLY STRETCHING SAID PREFORMED INSULATORWHEREBY TO PLACE SAID STRANDS IN TENSION AND TO INCREASE THE LENGTHWISEDIMENSION OF SAID STRANDS AND SAID SHEET TO APPROXIMATELY THE LENGTHWISEDIMENSION OF SAID BORDER FRAME, AND THEREAFTER WHILE SAID STRANDS ARE INTENSION AND SAID STRANDS AND SHEETS ARE INCREASED IN LENGTH ASAFORESAID, SECURING THE OTHER OF SAID ANCHORAGE MEMBERS TO THE OPPOSITEEND OF SAID BORDER FRAME.